Detailed Project Report (DPR) on o-pvc pipe manufacturing plant

O-PVC PIPE MANUFACTURING PLANT

[CODE NO.4134]  

PVC-O, is axially stretched and radially stretched PVC pipe, so that the long-chain PVC molecules in the pipe are arranged in a biaxial direction to obtain a new PVC pipe with high strength, high toughness, high impact resistance and fatigue resistance.

Molecularly Oriented PVC is the result of reorganizing the amorphous structure of PVC-U into a layered structured, by a mechanical process, to provide unbeatable mechanical properties in a plastic pipe, such as: high impact resistance (almost unbreakable), high stiffness and fatigue resistance, excellent behaviour with external loads, elimination of crack propagation and maximum ductility.

This reorganization or alignment is done through an elongation of the plastic in special conditions that allow the molecules to rotate following the direction of the deformation. Although these molecular changes are not visible at macroscopic scale, it is fully appreciable with an electronic microscope. As it is a physical process, there is no change chemically, so, there is no significant change to the PVC formulation.

PVC-O pipes are the best choice for high pressure pipe (piping) to be used for water conveyance. The latest technology PVC-O pipes have considerable advantages over the conventional pipes such as Ductile Iron pipe and HDPE pipes. The PVC-O pipes are easy in handling and laying compared to DI pipes and HDPE pipes. No heavy machineries or welding is required. The manufacturing of PVC-O pipes is the most ecofriendly amongst all the high pressure pipe manufacturers. Finally, it’s a food grade, green product. PVC is an amorphous polymer in which the molecules are arranged randomly. Under certain conditions of pressure, temperature and speed, by stretching, it is possible to orient the polymer molecules in the same direction as which the material has been stretched. Depending on the various process parameters and mainly stretch ratio, a higher or lower orientation degree is obtained. The result is plastic with a layered structure. The molecular orientation converts the amorphous structure into a layered structure. The layered structure gives the pipes desirable qualities such as pipe pressure withstanding capacity, lower wall thickness, zero crack propagation, resistance to traction and fatigue, flexibility, excellent response to water hammer and high impact resistance. The pressure ratings available are PN12.5, PN16, PN20 and PN25. The pipes are manufactured as per BIS standard IS 16647:2017. Our pipes have been used for various lift irrigation projects, pressurised water conveyance and water infrastructure projects in various Government departments. The various advantages of plastic pipes such as non-corrosive and the strength of metal pipes is combined here in oriented PVC (PVC-O) pipes. We have all the required PVC-O fittings to support a PVC-O piping system. The various PVC-O fittings available include 45° Elbows, 22.5° Elbows, 11.25° Elbows, sliding coupler, reducer, etc. All types of fittings required for a project including Tees and Flanges are also supplied as per customer requirement. Molecular Orientation reduces the pipe wall thickness, giving a greater internal diameter and flow section. Also, the internal surface of PVC-O Pipes is extremely smooth, reducing load loss and making it more difficult for deposits to be formed on the inner wall. This leads to 15-40% more hydraulic capacity than other pipes with the same external diameter. 

The quality of fluid that flows through the pipes always remains unaltered, given that PVC-O material neither suffers corrosion nor migration within the pipes. It is considered as the best application for high-pressure water transport, particularly drinking water, for water supply networks. PVC-O Pipes are lighter and easier to handle than other pipes and, in most cases, does not require machinery even for higher dimensions. Smooth and thinner wall results in higher amount of water flow and upto 30% savings in electricity cost. There is a positive stand out in terms of cost, performance and installation speed compared to other pipes. Immune to Corrosion and natural chemicals as well as micro and macro organisms, CCAL PVC-O pipes are not degradable. Also, no special protection or coating is required, thereby saving cost. Pipes are easy to join and can be installed by semi – skilled workers. 100% water-tight joints are guaranteed and do not displace once installed. PVC-O is the best solution for medium and high-pressure water networks for irrigation systems, potable water supply and pumping systems, among other applications.

COST ESTIMATION

Plant Capacity                                    7.2 MT/Day

Land & Building (5000 sq.mt.)          Rs. 4.14 Cr

Plant & Machinery                               Rs. 7.71 Cr

Working Capital for 2 Months            Rs. 3.53 Cr

Total Capital Investment                    Rs. 15.97 Cr

Rate of Return                                      36%

Break Even Point                                  47%

• INTRODUCTION
• PROJECT LOCATION – NEPAL
• MAP
• TRANSPORTATION
• HISTORY OF O-PVC PIPE
• TYPES OF O-PVC PIPE
• THE FOLLOWING ARE THE MENTIONED TYPES OF THE POLYVINYL CHLORIDE:
• UNPLASTICIZED POLYVINYL CHLORIDE (UPVC)
• CHLORINATED POLYVINYL CHLORIDE (CPVC)
• ORIENTED POLYVINYL CHLORIDE (OPVC)
• DIFFERENT TYPES OF ADDITIVES AND THEIR FUNCTIONS
• TYPES OF ADDITIVES
• FUNCTIONS OF ADDITIVES
• 1. PLASTICIZERS
• 2. STABILIZERS
• 3. LUBRICANTS
• 4. IMPACT MODIFIER
• 5. PIGMENTS
• 6. PROCESS AIDS
• 7. REINFORCEMENT
• 8. FLAME RETARDANT
• 9. FILLERS
• 10. COMPATIBILIZERS
• THE RAW MATERIALS OF POLYVINYL CHLORIDE (PVC)
• CHARACTERISTICS OF POLYVINYL CHLORIDE
• 1. VERSATILITY
• 2. FIRE RETARDING PROPERTIES
• 3. DURABILITY
• 4. CHEMICALS RESISTANT
• 5. MECHANICAL STABILITY
• 6. PROCESSABILITY AND MOULDABILITY
• FEATURES
• TECHNICAL SPECIFICATION OF O-PVC PIPE
• FEATURES OF PVC-O CLASS 500 PIPES
• SPECIFICATION LIST
• ADVANTAGES OF PVC-O PIPE
• ADVANTAGES OF PVC-O PIPES OVER DUCTILE IRON PIPES (DI PIPES)
• USES AND APPLICATION
• APPLICATION OF PVC-O PIPE
• B.I.S. SPECIFICATION
• PROCESS FLOW CHART
• MANUFACTURING PROCESS
• 1. RAW MATERIALS
• 2. MANUFACTURING PROCESS
• 3. CONTROL POINTS
• 4. ENVIRONMENTAL AND HYGIENIC CONDITIONS
• EXTRUSION PROCESS
• WORKING PRINCIPLE
• EXTRUSION PROCESS PARAMETERS
• THERE ARE FIVE IMPORTANT PROCESS PARAMETERS TO BE CONSIDERED 
• BEFORE EXTRUSION PROCESS:
• ADVANTAGES:
• DISADVANTAGES:
• DESCRIPTION OF MANUFACTURING PROCESS:
• INCOMING RAW MATERIAL INSPECTION
• RESIN HANDLING FOR MOISTURE CONTENT AND TEMPERATURE
• RESIN STORAGE AND CONVEYANCE
• RESIN FEEDING
• 2. SIZING:
• 3. TRACTION:
• 4. CUTTING:
• QUALITY CONTROL
• GENERAL REQUIREMENTS OF PIPES
• 1. VISUAL APPEARANCE
• 2. COLOUR
• 3. OPACITY
• INSPECTION AND TESTING
• 1. LOT AND CONTROL UNIT
• 2. TESTS ON RAW MATERIAL
• 3. TESTS ON PIPES
• TESTING
• (A) TYPE TEST
• (B) ACCEPTANCE TEST
• (C) MARKING
• MARKET POSITION
• PVC PIPING INDUSTRY DEVELOPMENT IN INDIA
• INDIA PVC PIPES MARKET IS STUDIED BY VARIOUS SEGMENTS:
• MARKET INSIGHTS
• THE DEMAND FOR PVC IN INDIAN MARKET IN THE NEAR FUTURE
• MARKET GROWTH
• KEY FINDINGS OF THE INDIA PVC PIPE MARKET:
• SUPPLIERS OF O-PVC PIPE
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF PVC RESIN GRANULE
• SUPPLIERS OF PLASTISIZERS
• SUPPLIERS OF PVC STABLIZERS
• SUPPLIERS OF CALCIUM STERATE
• SUPPLIERS OF STEARIC ACID
• SUPPLIERS OF CHINA CLAY
• SUPPLIERS OF PIGMENTS
• SUPPLIERS OF PLANT AND MACHINERY
• SUPPLIERS OF PRECISION MEASURING TOOLS
• SUPPLIERS OF EOT CRANES
• SUPPLIERS OF POWER TRANSFORMERS
• SUPPLIERS OF ELECTRICAL PANEL
• SUPPLIERS OF COOLING TOWER
• SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
• SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
• SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
• SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
• PRINCIPLES OF PLANT LAYOUT
• MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
• PLANT LOCATION FACTORS
• 1. RAW-MATERIAL SUPPLY:
• 2. MARKETS:
• 3. POWER AND FUEL SUPPLY:
• 4. WATER SUPPLY:
• 5. CLIMATE:
• 6. TRANSPORTATION:
• 7. WASTE DISPOSAL:
• 8. LABOR:
• 9. REGULATORY LAWS:
• 10. TAXES:
• 11. SITE CHARACTERISTICS:
• 12. COMMUNITY FACTORS:
• 13. VULNERABILITY TO WARTIME ATTACK:
• 14. FLOOD AND FIRE CONTROL:
• EXPLANATION OF TERMS USED IN THE PROJECT REPORT
• 1. DEPRECIATION:
• 2. FIXED ASSETS:
• 3. WORKING CAPITAL:
• 4. BREAK-EVEN POINT:
• 5. OTHER FIXED EXPENSES:
• 6. MARGIN MONEY:
• 7. TERM LOANS:
• 8. TOTAL LOAD:
• 9. LAND AREA/MAN POWER RATIO:
• PROJECT IMPLEMENTATION SCHEDULES
• INTRODUCTION
• PROJECT HANDLING
• PROJECT SCHEDULING
• PROJECT CONSTRUCTION SCHEDULE
• TIME SCHEDULE
• RAW MATERIAL PHOTOGRAPHS
• PVC RESIN GRANULE
• PLASTISIZERS
• PVC STABLIZERS
• CALCIUM STERATE
• STEARIC ACID
• CHINA CLAY
• PIGMENTS
• MACHINERY PHOTOGRAPHS
• PRODUCT PHOTOGRAPHS

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)